Fondital FORMENTERA KC 24 Instructions Manual
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Fondital FORMENTERA KC 24 Instructions Manual

Wall-mounted condensing boilers
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INSTRUCTION MANUAL
Wall-mounted
FAMILY:
condensing boilers
Instantaneous with
GROUP:
forced draught
Formentera
MODELS:
Condensing
For indoor
VERSIONS:
installation
AST 14 C 257/00
CODE:
______________________________________________
st
1
edition, February 2013

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Summary of Contents for Fondital FORMENTERA KC 24

  • Page 1 INSTRUCTION MANUAL Wall-mounted FAMILY: condensing boilers Instantaneous with GROUP: forced draught Formentera MODELS: Condensing For indoor VERSIONS: installation AST 14 C 257/00 CODE: ______________________________________________ edition, February 2013...

  • Page 2: Table Of Contents

    Contents SECTION 01 TECHNICAL FEATURES 1.1 – Models 1.2 – Overall Dimensions 1.3 – Technical Data ___________________Page SECTION 02 TOUCH-SCREEN CONTROL PANEL AND DIAGNOSTICS 2.1 – User Interface 2.2 – LCD 2.3 – Boiler Status and Error Codes ___________________Page SECTION 03 PLUMBING DIAGRAMS AND COMPONENTS 3.1 –...
  • Page 3 ________________________________________________________________________________ AST 14 C 257/00...

  • Page 4: Models

    SECTION 1 TECHNICAL FEATURES 1.1 MODELS FORMENTERA Condensing KC 24 - 28 – 32 FORMENTERA Condensing KR 24 - 28 - 32 KEY TO SYMBOLS condensing combined heating-only MAIN FEATURES • FORMENTERA Condensing KC 24 – 28 - 32: combined instantaneous condensing boiler for indoor installation, with DHW+heating, sealed chamber, forced draught, mono-thermal with plate exchanger •...
  • Page 5 Front view Side view View from b elow View from ab ove Gas inlet (1/2”) Heating system flow (3/4”) CH return (3/4”) Cold w ater inlet (1/2”) Hot w ater outlet (1/2”) ________________________________________________________________________________ AST 14 C 257/00...
  • Page 6 INSTALLATION DIAGRAM ________________________________________________________________________________ AST 14 C 257/00...

  • Page 7: Technical Data

    1.3 TECHNICAL DATA General Features KC-KR 24 KC-KR 28 KC-KR 32 Operating parameters Category II2H3P Burner nozzles Minimum CH circuit flow rate Maximum and minimum CH pressure 3-0.5 Maximum and minimum DHW circuit pressure 6-0.5 DHW specific flow rate û t 30°C l/min 13.5 15.5...
  • Page 8 Design data and stack size KC-KR 24 Max. heat Min. output 30% load output Casing heat loss with burner off 0.28 Casing heat loss with burner on 0.97 6.49 Flue system heat loss with burner on 2.62 2.09 Flue (natural gas) mass flow rate 12.43 1.33 Flue gas / air temperature...
  • Page 9 Settings KC-KR Max heat MIN-MAX Gas mains No. of Diameter MIN-MAX input heat output inlet pressure nozzles nozzles value (kW) (kW) (mbar) (mm) (%) +/- 0.1 23.7 2.7 – 22.9 (60-80°C) 9.3-9.0 natural gas 3.2 – 24.9 (30-50°C) 3.0 – 27.4 (DHW)) 23.7 10.0-10.0 propane gas...

  • Page 10: User Interface

    SECTION 2 TOUCH-SCREEN CONTROL PANEL AND DIAGNOSTICS 2.1 USER INTERFACE Im portant: Touch the button area to access the various settings. This activates backlighting (keys + LCD) and access to the various functions. To guide the user, only active buttons are backlit. One minute after the last button has been touched, the interface is disabled and the light sw itches off.
  • Page 11 2.2 LIQUID CRYSTAL DISPLAY (LCD) Sym bol Description Boiler operating m ode indicator These icons indicate the current operating mode: : only icon comes on SUMMER icons come on SUMMER and WINTER: both CENTRAL HEATING ONLY only the icon comes on : OFF STANDBY comes on...

  • Page 12: Boiler Status And Error Codes

    Fan rpm indicator It switches on, together with the relevant symbol when the chimney-sweep function is activated. It indicates the fan rpm alternatively with the flow temperature. SUPER-TECHNICAL param eter indicator When displayed simultaneously with the parameter display indicator, it indicates the super-technical parameters programming mode.
  • Page 13 Boiler in SUMMER mode. DHW function active w ith flame lit. The DHW temperature and the burner output percentage are displayed. Boiler in SUMMER or WINTER mode. DHW function active w ith flame lit. The DHW temperature and the burner output percentage are displayed.
  • Page 14 Boiler shutdow n due to flame absence Boiler shutdow n due to double flow probe intervention Boiler shutdow n due to flue gas thermostat intervention Boiler shutdow n due to low system pressure Boiler shutdow n due to flow probe fault (f) Boiler shutdow n due to DHW probe fault (f) Boiler shutdow n due to flue gas probe fault (f) System pressure too high...
  • Page 15 Failure on flow probe of mixed zone 3 (f) Failure on flow probe of mixed zone 4 (f) Boiler shutdow n due to fan fault No communication betw een peripherals: additional interface or board Plumbing configuration not allow ed Zone configuration error (remote control and ambient thermostat) Pressure transducer fault (f) Communication error betw een the main board and the...
  • Page 16 Flow probe o return probe > 120 C° Shutdow n due to max. flow derivative threshold exceeded Shutdow n due to max. return derivative threshold exceeded Pow er reduction due to high flue gas temperature* Maximum number of remote reset attempts reached * Errors E81, 82, 83, 84 and 88 are not displayed in real time.

  • Page 17: Plumbing Diagrams

    SECTION 3 PLUMBING DIAGRAMS AND COMPONENTS 3.1 PLUMBING DIAGRAMS 1. Condensate drain trap 20. 3-bar safety valve 2. Modulating gas valve 21. Discharge tap 3. Heating temperature sensor 1 22. Pressure transducer 4. Heating temperature sensor 2 23. 13-14 l/min flow-limiting device 5.
  • Page 18 1. Condensate drain trap 15. Return temperature sensor 2. Modulating gas valve 16. 3-bar safety valve 3. Heating temperature sensor 1 17. Pressure transducer 4. Modulating fan 18. De-aerator 5. Primary condensing exchanger 19. Circulation pump 6. De-aerator 20. Discharge tap 7.

  • Page 19: Plumbing Assembly

    3.2 PLUMBING ASSEMBLY MOTORISED THREE-WAY VALVE (Version KC only) The boiler uses a three-way valve to divert the water flow from one pipe to another. The valve conveys the primary circuit water to the secondary exchanger, where heat is transferred to the DHW. The valve consists of a brass main body, a cartridge made of composite material (35% glass-reinforced nylon), and an electric motor (actuator) to operate the internal shutter.
  • Page 20 Three-way valve view: THERMOPOLYMER CARTRIDGE SHUTTER ACTUATOR 3-WAY VALVE STATUS Shutter pointing up Actuator piston home Heating Shutter pointing down Actuator piston thrust The boiler is fitted with an automatic bypass and a non-return valve, with an opening threshold of 400 mb ar. In the event of system load losses due to intervention of the thermostatic valve, the bypass ensures a minimum flow inside the primary exchanger.
  • Page 21 The terminal block of the circulation pump has a 3-position selector that intervenes on the motor rotation speed and consequently on the plant head for all capacities, the only different element (depending on the primary exchanger) is the residual head curve. 24 kW Flow rate [l/h Flow rate [l/h...
  • Page 22 DHW FLOW METER/SWITCH (Version KC only) The DHW flow meter contains a magnet switch, the position of which determines the minimum amount of domestic water needed to start up the boiler (3 l/min ON and 1 l/min . If the request for DHW does not exceed this value, the microswitch does not close OFF) the contact, which prevents the boiler from switching on and avoids the risk of boiling at very low flow rates.
  • Page 23 EXPANSION VESSEL An increase in the temperature of the water in a closed-circuit heating system corresponds to an increase in water volume . As there is no more space available, what increases is the pressure, not the water volume. If the pressure exceeds the safety valve activation point, the valve opens and discharges water from the system.

  • Page 24: Primary Condensing Exchanger

    3.3 PRIMARY CONDENSING EXCHANGER The heat exchanger contains oval stainless steel spiral pipes, which are coiled up during manufacture. There is no welds in the hot parts of the exchanger, those in contact with the flame. The exchanger features weak heat inertia and high resistance to corrosion. The outside is coated with thermopolymer plastic materials.
  • Page 25 Inside the module, the return pipe is in the coldest zone (condensing chamber) to ensure flue gas condensing and water pre-heating so that the water temperature is higher when flowing into the combustion chamber. This decreases fuel consumption and prevents the formation of condensate, which would drip onto the burner and damage it.

  • Page 26: Pre-Mix Burner

    3.4 PRE-MIX BURNER A cylindrical stainless steel burner is mounted on the exchanger with an aluminium flange. Inside the flange is a silicone seal (which must be replaced every two years during maintenance) and a flue gas and condensate sealing plait. Overheating is prevented by ceramic-fibre insulation.

  • Page 27: Fan Unit And Gas Valve

    3.5 FAN UNIT AND GAS VALVE When the fan is powered on, it generates a vacuum along the fan-gas valve connection pipe that depends on the air flow rate. When the gas valve is powered on, there will be a negative pressure at the outlet, and the valve will regulate the gas flow rate based on this vacuum, and hence the fan speed.
  • Page 28 MODULATING FAN The fan ensures a constant air flow during the modulation range, from maximum to minimum thermal output. The fan speed changes with the modulation power provided by the board and the type of boiler, as shown in the table below. This speed variation is due to the request for heat and the temperature measured by the NTC heating and DHW probes.
  • Page 29 SIT 848_135 GAS VALVE GAS OUT Minimum power adjusting screw Maximum power adjusting screw Compensation pressure point Pressure measurement point Gas inlet GAS IN Gas valve features SIT 848_135 SV1 and SV2 safety coil pow er supply 230V AC 50 Hz SV1 operating current 40 mA 12 mA...
  • Page 30 The valve has a compensation pressure port that is connected to the combustion chamber by means of a silicone tube. The valve reads the pressure at the nozzles and can supply the correct quantity of gas, even in the event of an overpressure or vacuum inside the chamber. On ignition, for example, when the fan is activated, a vacuum develops inside the combustion chamber, and the valve (thanks to this pressure port) decreases the nozzle pressure to offset any excess gas supplied due to the vacuum.
  • Page 31 AIR/GAS MIXER The air/gas mixture is generated inside the mixer, thanks to air flow via the vacuum developed by the fan, and sent to the gas valve mechanism. When the fan is powered on, it creates a vacuum proportional to its speed, giving a mixture with a constant ratio from maximum to minimum power.

  • Page 32: Flue Gas Venting And Condensate Drain System

    3.6 FLUE GAS VENTING AND CONDENSATE DRAIN SYSTEM The boiler has a tower for connecting the suction/discharge pipes, with holes allowing direct access to the combustion air and flue gas outlet (sampling points for calculating the combustion efficiency). Before taking readings, you need to remove the caps. Insert the flue gas probe of the analyser in the right-hand hole and the ambient probe in the left-hand hole: Condensate collection tray...

  • Page 33: Gas Valve Setting

    SECTION 4 GAS SETTING AND TSP PARAMETERS 4.1 GAS VALVE SETTING Procedure for regulating the gas valve ƒ Check the static mains pressure via the inlet, referring to the table of settings on page 8 (pressure values lower than required do not guarantee correct boiler operation).
  • Page 34 4.2 CHIMNEY-SWEEP FUNCTION The boiler has a chimney-sweep function, which used to measure combustion efficiency during use and to adjust the burner. This function can only be activated in HEATING + DHW mode. To do so, press the reset button for more than three seconds. The boiler will now perform the ignition sequence and operates at the maximum burner output established by parameter P4.

  • Page 35: Gas Conversion

    Table of minimum values: 24 kW 28 kW 32 kW 42 Hz 40 Hz 43 Hz When the +/- DHW buttons are released, the previous page will be displayed, the one showing the fan rpm and flow temperature. The burner switches off when the temperature read by the flow probe exceeds 90°C and switches on again when it reaches 70°C.
  • Page 36 ƒ Disconnect the gas pipe from the mixer. ƒ Unscrew the three socket head screws and remove the mixer. ƒ Take the mixer apart (see diagram). ƒ Remove the two burner nozzles using a 6mm Allen wrench. ƒ Mount the new nozzles and screw them in but do not overtighten. IMPORTANT.
  • Page 37 4.4 PARAMETERS The boards stores a series of parameters. You can access them merely to view them, or you can modify them to achieve a better boiler configuration based on the system used. These parameters can be accessed directly via the user interface, or the remote control. In the latter case, you can only view/modify up to parameter 29.
  • Page 38 Changing the SUPER-TECHNICAL parameters You can access programming of the super-technical parameters by pressing the reset and b oiler status buttons for three seconds. They are displayed in sequence after parameter Cod means you have to enter a code (default 139) using of the +/– heating buttons (press OK to confirm each number).
  • Page 39 Parameter display (read-only) By repeatedly pressing the OK-info button, you can scroll through the values of the read- only parameters (P30 to P50), such as the temperature read by the various probes connected. Press Reset to exit display mode. The display will return to its initial status automatically 60 seconds after the last button has been touched.
  • Page 40 18 = 24 kW natural gas 25 = 28 kW natural gas 0-300 s 18 = 24 kW propane gas (1=10s) (180 s) 25 = 28 kW propane gas Negative ramp time 18 = 32 kW natural gas 18 = 32 kW propane gas With external probe: Low temp.
  • Page 41 0 = pump + diverting valve Plumbing operation selection (heating-only 1 = double pump version) 0 = OFF Default parameter setting except for P0-P1- 1 = default parameters P2-P17 and P28 Displayed only with Outside temperature display external probe connected Flow temperature display Displayed only with Nominal calculated flow temperature...
  • Page 42 0 = flow temperature 1 = not admitted 2 = not admitted 3 = outside temperature 4 = tank heater temp. Type of temperature display 5 = solar collector temp. 6 = solar valve temp. 7 = solar valve temp, from PAVO Max.
  • Page 43 0 = standard function Multifunction relay override 1 = energised relay 0 = standard function 1 = energised relay Zone 2 pump relay override 0 = standard function 1 = force on opening Zone 2 mixing valve override 2 = force on closure 0 = standard function Zone 3 pump relay override 1 = energised relay...

  • Page 44: Main General Characteristics

    SECTION 5 OPERATING LOGIC 5.1 MAIN GENERAL CHARACTERISTICS ƒ Function priority ƒ Boiler configuration ƒ Ignition phase at pre-set output ƒ Flame propagation at the pre-set output ƒ Automatic flame control ƒ DHW control ƒ DHW plate system modulation ƒ Tank heater DHW modulation ƒ...
  • Page 45 BOILER CONFIGURATION This board can be used to configure 3 different types of boiler, according to parameter P3 setting: P3 = 1 Æ instant plate comb i (model KC) P3 = 2 Æ heating only (future implementation) P3 = 3 Æ heating only with tank heater (model KR) IMPORTANT: For this model, this parameter must be set to 1.
  • Page 46 Flame IGNITION PHASE AT PRE-SET OUTPUT detected At each request entailing burner ignition, the burner will ignite with a pre-set power according to parameter P6 (fan speed at burner ignition power). Once the flame has been detected, flame propagation phase will commence. Flame propagation FLAME PROPAGATION PHASE AT PRE-SET POWER...
  • Page 47 Logic diagram for boiler operation Shutdown Blocc o Detection R ilevazione Functions Funzioni Ac c ensione Switch-on Pressostato aria Flue gas T erm ostato fum i thermostat Elettrovalvola Solenoid valve Combustion fan Ventilatore di c om bustione ON/OFF Time for checking air pressure T em po verifica pressostato aria Times switch or flue gas thermostat...
  • Page 48 DHW modulation modulation (PID) ,I DW PLQLPXP KHDW RXWSXW WKH WHPSHUDWXUH UHDG E\ WKH '+: SUREH FRQWLQXHV WR ULVH WKH ERLOHU ZLOO VZLWFK RII DW D FHUWDLQ SRLQW Time If the thermal efficiency of the plate exchanger is low due to clogging and hence over- temperature of the primary body, PID-type adjustment of the flow is required in addition to DHW modulation.
  • Page 49 N.B. If a b oiler is comb ined with a solar plant with instantaneous integration, we recommend setting the parameter P14 to 1. This increases the modulation range and avoids b oiler hunting (starting and stopping) with the inlet temperature very close to the set-point.
  • Page 50 HEATING CONTROL With the boiler in DHW+HEATING or Only Heating mode, closing of the ambient thermostat electrical contact (as well as consent from the remote control or the zone board) generates a request, leading to Heating modulation. IMPORTANT. With parameter P16, it is possible to delay the ambient thermostat reading to allow the zone valves to open prior to activation of the boiler pump (from 0 to 199 seconds).
  • Page 51 During the heating phase: with P17 = 1 (multifunction relay in remote relay/TA1), the relay is energised and returns to the off-state when there is a DHW request or the boiler is switched to OFF or DHW ONLY mode; with P17 = 3 (multifunction relay in TA2 request), the relay is energised and returns to the off-state when there is a DHW request or if the boiler is switched to OFF or DHW ONLY mode.
  • Page 52 Heating modulation temperature - reduced range (P10<1): ƒ Heating temperature setting reduced range: 20-45°C ƒ Reduced heating thermostat intervention temperature: OFF = set-point + 2°C ƒ Reduced heating thermostat intervention temperature: ON = set-point - 2°C ƒ Heating thermostat timer (anti-fast) via parameter P11: 0-10 min, default 4 min with Tflow > ƒ...
  • Page 53 Setting the thermoregulation curve Press the Reset and b oiler status buttons together for three seconds to access the parameter programming mode. Use the +/- heating buttons to select parameter P10. Press OK to confirm that you want to modify the value of the parameter. The spanner symbol means that you can do this with the +/- heating buttons: Press OK-info to confirm and press Reset to exit the programming mode.
  • Page 54 CURVE OUTSIDE TEMPERATURE The above curves refer to a fictitious amb ient temperature of 20°C. If a temperature other than 20°C is requested, all the curves move in a parallel. Example of a curve shift w ith P10=1.5, w ith a fictitious ambient temperature from 20°C to 25°C: Choosing a curve can either be performed mentally or using a mathematical formula.
  • Page 55 Mathematical formula – use the following formula: − Tmax CURVE − Testmin where Tmax is the maximum flow temperature and Testmin is the minimum outside temperature. Example: Low temperature: High temperature: Tmax = 44°C Tmax = 70°C Test = -10°C Test = -10°C −...
  • Page 56 PROVISION FOR OPENTHERM REMOTE CONTROL The control board is provided with an internal interface that allows the connection of an OpenTherm protocol-based remote control. Besides serving as an ambient thermostat for its zone, it is used for setting some of main boiler parameters. The remote control must be connected to the board using two non-polarised wires, and when the connection is completed, the word “Con”...
  • Page 57 • P17=1 Remote reference The relay is energised with each request from the remote control (or TA1) REMOTE CONTROL AMBIENT THERMOSTAT Electrical connections: SOLENOID VALVE SOLENOID VALVE WITH LIMIT SWITCH 21 22 23 • P17=3 Ambient thermostat reference The relay is energised with each request from amb ient thermostat TA2 AMBIENT THERMOSTAT SOLENOID VALVE AMBIENT...
  • Page 58 • P17=2 Solar reference: BOILER INTEGRATION (P18=0) The diverting valve (VM) of a solar panel system is handled: TANK HEATER SOLAR PANEL MAINS WATER SUPPLY Double-acting valve Single-acting valve Electrical connections: neutral neutral to the collector in the boiler to the collector 21 22 23 21 22 23 This function consists of controlling the motorised valve VM, via the multifunction relay,...
  • Page 59 • P17=2 TANK HEATER LOAD solar reference (P18=1) Control of the pump (PS) of a forced-type solar panel system Electrical connections: 21 22 23 SOLAR PANEL SOLAR UNIT TANK HEATER MAINS WATER SUPPLY Under specific conditions, this function activates the solar pump, via the multifunction relay, to heat a tank heater.
  • Page 60 Tank heater load conditions (pump OFF): The PS solar pump is deactivated under the following conditions: • Tsb s > P19 • Tscs – Tsb s < ¨ T OFF (P21) • Tscs < Tmin pump collector OFF (P23-5°C) • Tscs > Tmax pump collector OFF (P22) where Tsbs is the temperature read by the solar tank heater probe, and Tscs is the temperature read by the solar collector probe.
  • Page 61 The function ends with the PS switching off under the following conditions: Tsb s < P19 Tscs > Tsb s-¨ T OFF (P21) This function cannot be performed if the solar tank heater (SBS) temperature probe is faulty. IMPORTANT. The tank heater cooling function is normally disab led. Set parameter P26 to 1 to activate it.
  • Page 62 RS connection and settings Regardless of the number of boards ZONE2 used, each board must be connected to the boiler board in cascade via an RS485 connection, as shown in the diagram on the right: K/>Z ZONE3 K Z ZONE4 ^,  > / SOLAR...
  • Page 63 Wiring diagrams The heating zones 1 and 2 can be controlled by the remote control (TA1) or the ambient thermostat (TA2) that can be connected to the boiler boards; zones 3 and 4 are activated directly by the ambient thermostat connected to the relevant zone board. Zones 3 and 4 cannot support control by the safety flow line thermostat (TSM), which must be mounted in series on the pump power supply line and will not be detected as a fault.
  • Page 64 The zone board also comes with a bi-colour LED showing the following indications: Green Æ pump active; Red, quick b linking Æ valve opening; Red, slow b linking Æ valve closing; Green flash Æ boards w ith no request; Red, very slow b linking (1s on, 1s off) Æ communication w ith boiler board not w orking;...
  • Page 65 Zone 4: Parameter P70 setting to enter the thermoregulation curve (with an external probe) or the operating range (without an external probe). Regulation via parameter P71 of the fictitious ambient temperature (with an external probe) or the set-point flow value (without an external probe) according to the selected range. Parameter P39 displays the calculated flow temperature, and parameter P40 the current one detected by the boiler probe N.B.
  • Page 66 Tank heater filling function (pump ON) The tank heater temperature is set, via parameter P19, to a value between 10 and 90°C ( default 60°C The PS solar pump is activated under the following conditions: • Tsvs < P19-2°C • Tscs –...
  • Page 67 Heat dissipation from the collector If the solar tank heater reaches the set temperature, this function prevents the solar collectors from stagnating for a long time, which may cause them high thermal stress. For this reason, the PS solar pump is reactivated according to the following logic: Tscs >...
  • Page 68 Important. The solar collector anti-freeze function is only enab led if parameter P24 is set to 1, whereas the b oiler mode has no effect on this function. Solar characteristics When the solar pump activates, the boiler display shows the icon indicating that the pump is active.
  • Page 69 ¾ Flow probe failure (E05): the burner switches off immediately and the fan runs at the ignition power. The pump runs until the fault is removed, with the diverting valve in the heating position if before the fault there was a request for heating, flow-return anti-freeze or chimney-sweep, or there were no request at all.
  • Page 70 ¾ Solar probe failure (E24, E27, E28): With P18=0, if the solar tank heater probe (SBS) fails, the VM diverting valve moves to the solar-only position (no integration by the boiler). With P18=1, if the failure involves the solar tank heater probe (SBS) or the solar collector probe (SCS), the PS solar pump switches off.
  • Page 71 BRUSHLESS FAN CHECK The fan speed is constantly monitored to check for any faults. On standby (fan in the home position), if the speed exceeds 500 rpm for more than 30 seconds, a fan alarm signal will be generated with consequent shutdown. At the start of the rotation request, the speed read must be greater than 700 rpm, and within the maximum set fan speed tolerance (set-point ±...
  • Page 72 PLATE DHW ANTI-FREEZE FUNCTION The DHW NTC probe measures the temperature of the DHW. When this value falls below 5°C, a request for DHW anti-freeze operation is generated. The pump activates and after a 30-second delay, the burner ignites with the output forced to the minimum value. During DHW anti-freeze operation, the temperature read by the flow probe is kept monitored, and if it reaches 60°C the burner switches off.
  • Page 73 PUMP POST-CIRCULATION FUNCTION At the end of a heating, anti-freeze or chimney-sweep request, the burner (if ON) switches off immediately. The pump continues to be powered for 30 sec (this time can be adjusted via parameter P13). The same applies to the multifunction relay with P17=1 or P17=3 at the end of each request by the remote control or the associated ambient thermostat.
  • Page 74 Flue gas thermostat (E03 shutdown) The flue gas thermostat (inserted in the discharge Therm ostat 105°C tower) is a normally closed contact connected in series with the gas valve operator, and is directly controlled by the automatic flame device. When the contact is open, the gas valve power supply is immediately interrupted, and if it remains open for a time >...
  • Page 75 Flue gas probe Correct op. temp. range -20°C to +180°C Double flow probe (shutdown E02) Overheating control is performed by the double probe located on the flow pipe in place of the classic contact safety thermostat. When a temperature of 105°C is reached, the power supply to the gas valve cuts off immediately and the E02 error message is displayed.
  • Page 76 Maximum flow and return deviation check function (E80 shutdown) This check is carried out before each burner ignition request different from the instantaneous DHW. After pump activation, wait 10 seconds and then check the temperature differential which must be between the range specified below. û...
  • Page 77 Below is an overview of the different situations. Type of Lim it w ater flow Burner ON Burner OFF Output Error request rate tim e tim e [ kW] [l/h] [min] Heating, anti- 1 min freeze, 2 min chimney- sweep 3 min 24 kW Plate DHW,...
  • Page 78 SECTION 6 ELECTRICAL SYSTEM 6.1 ELECTRONIC BOARD The boiler is controlled by two electronic boards, a main board and an interface board. The former is the boiler hardware and also incorporates the ignition transformer. The latter can be used to control the boiler via a touchscreen interface and an LCD. Communication between the two boards is performed via a cable with an RS485 connection, powered at 24V.

  • Page 79: Outer Terminal Box Electrical Connections

    6.2 OUTER TERMINAL BOX ELECTRICAL CONNECTIONS All the electrical connections are made via the terminal box situated on the back of the control panel. The additional boards (used to control the zones or complex panel solar systems) are housed is an external casing on the back of the control panel: Electrical Additional board...

  • Page 80: Wiring Diagram

    6.3 WIRING DIAGRAM Legend: pressure transducer NTC flue gas 10k Ohm flow switch MVD: motorised diverting valve NTC DHW probe 10k Ohm gas valve SRT: NTC return probe 10k Ohm boiler circulation pump flue gas thermostat SM1: NTC heating probe1 10k Ohm ignition/detection electrode SM2: NTC heating probe2 10k Ohm...

  • Page 81: Co-Axial Air/Vent Ducts

    SECTION 7 VENT DUCTS AND PIPES For the air intake/flue gas venting system, specific manufacturer-approved, condensate acid-resistant pipes and systems must be used, resistant to the etching of condensate acids. Flue gas venting pipes are to be installed at an angle towards the boiler so as to allow condensate to run towards the combustion chamber, which is designed for condensate collection and drainage.
  • Page 82 Dimensions for connecting flue gas exhaust pipes to co-axial ducts Gasket Closing ________________________________________________________________________________ AST 14 C 257/00...

  • Page 83: Split Air/Vent Ducts

    7.2 125/80 CO-AXIAL AIR/VENT DUCTS Type of installation: C13 - C33 Maximum pipe length* TYPE OF PIPE KC 24 KC 28 KC 32 INSTALLATION MATERIAL KR 24 KR 28 KR 32 Flue gas Max L [m] Max L [m] Max L [m] Air intake vent C13 –...
  • Page 84 Table of load losses in 80/80 split ducts Vent Intake Part 24 kW 28 kW 32 kW 24 kW 28 kW 32 kW Wall vent terminal 1m extension 0.5m extension 90° elbow 45° elbow 80mm tee with condensate drain 80mm tee 0.45m telescopic extension Flue gas intake/vent chimney Ø...
  • Page 85 7.4 Ø 60 SPLIT VENT DUCT Maximum pipe length Type of installation: B23 - B53* TYPE OF PIPE KC 24 KC 28 KC 32 INSTALLATION MATERIAL KR 24 KR 28 KR 32 Flue gas Max L [m] Max L [m] Max L [m] Air intake vent ----...
  • Page 86 NOTES _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ ________________________________________________________________________________ AST 14 C 257/00...
  • Page 87 TROUBLE-SHOOTING CHART Boiler Status Malfunction Probable cause Solution Check gas pressure. Check gas supply tap or Gas supply failure gas network safety valve intervention. Burner does not ignite Gas valve disconnected Reconnect it. Gas valve faulty Replace it. Board faulty Replace it.
  • Page 88 Boiler shutdown, message Low water inside heating Fill up system. flashing: system CH system water pressure is low Leaks in the CH system Check the system. One of the two probes is Reconnect or Boiler shutdown, message disconnected or has short- replace the probe.
  • Page 89 Boiler shutdown, message flashing: External probe not Probe disconnected or Reconnect the probe or working faulty replace it, if necessary. Boiler shutdown, message Probe disconnected or Reconnect the probe or flashing: Failure on the solar faulty replace it, if necessary. collector probe SCS (connected to the boiler The probe detects a...
  • Page 90 Boiler shutdown, message Obstructions inside the Check for any obstruction Fan rpm v alue not flashing: flue gas duct inside the flue gas duct. corresponding to the Faulty fan Replace the fan. required v alue Faulty boiler board Replace the boiler board. Fan failure Fan wrongly connected Check the connections.
  • Page 91 Boiler shutdown, message flashing: Safety circuit hardware Replace the main board. failure (gas valve relay) Boiler shutdown, message flashing: Boiler board and interface Incompatibility board don't belong to the Check boiler board and betw een boiler board same type: atmospheric / interface board type and interface board condensing...
  • Page 92 Bleed the boiler by opening the outlets on Boiler shutdown, message Air inside the boiler the heat exchanger and flashing: Maximum flow threshold pump. exceeded Check there are no Circulation of extraneous other boilers in a hot water in the boiler cascade connection, or supplementary sources.
  • Page 96 FONDITAL GROUP Formentera Condensing Technic Manual Customer Service Department 1st edition, February 2013 AST 14 C 257 – 00...

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